Front Suspension: Removal & Installation Lexus ES XV30

Removal

1. Remove axle hub sub-asssembly. See «AXLE HUB SUB-ASSEMBLY»(ref-156462-S31013820412003072100000).
2. Using Special Tool (09950-00020, 09950-60010 (09951-00410), 09950-70010, (09951-07100) and a press, remove inner race (outside) from axle hub sub-assembly. (Scheme 3)
3. Using a torx wrench (T30), remove bolts and disc brake dust cover.
4. Place the inner race (outside) on the axle hub bearing. Using Special Tool (09527-17011, 09950-60010 (09951-00600), 09950-70010 (09951-07100) and a press, press the axle hub bearing until in contacts special tool.
5. Using a spanner to make the steering knuckle horizontal, fix to "V" block as shown. (Scheme 4)
6. Using Special Tool (09950-60010 (09951-00600), 09950-70010 (09951-07100) and a press, remove axle hub bearing.

Scheme 3

Scheme 4

Installation

1. Using Special Tool (09950-60020 (09951-00790), 09950-70010 (09951-07100) and a press, install NEW axle hub bearing to steering knuckle. (Scheme 5)
2. Install disc brake dust cover and, using a torx wrench (T30), torque bolts.
3. Install axle hub sub-assembly. See «AXLE HUB SUB-ASSEMBLY»(ref-156462-S31013820412003072100000).

Scheme 5

1. Remove front wheel.
2. Using Special Tool (09930-00010) and a hammer, unstake the front axle hub nut. Loosen the staked part of the lock nut completely or the threads of the drive shaft may be damaged. (Scheme 6)
3. While applying brakes, remove the axle hub nut.
4. Remove bolt, disconnect flexible hose No. 1 and speed sensor. (Scheme 7)
5. Remove bolts and disconnect front disc brake caliper assembly from drive shaft assembly. (Scheme 8)
6. Remove disc.
7. Remove cotter pin and nut of tie rod assembly. Using Special Tool (09628-62011), disconnect tie rod assembly from steering knuckle. (Scheme 9)
8. Disconnect suspension arm lower sub-assembly No. 1. See «SUSPENSION ARM LOWER SUB-ASSEMBLY NO. 1»(ref-156462-S07961873212003071800000).
9. Using a plastic hammer, separate the front drive shaft assembly from axle hub sub-assembly. Be careful not to damage boot and ABS speed sensor rotor. Remove bolts, nuts and steering knuckle with the axle hub.
10. Remove lower ball joint assembly. See «LOWER BALL JOINT ASSEMBLY»(ref-156462-S21650614062003071800000).
11. Using a snap ring plier, remove front axle hub snap ring.
12. Using Special Tool (09520-00031), remove axle hub sub-assembly. (Scheme 10)

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

1. Using Special Tools (09608-32010, 09950-60020 (09951-00790), 09950-70010 (09951-07100) and a press, install axle hub sub-assembly. (Scheme 11)
2. Using snap ring plier, install NEW axle hub snap ring.
3. Install lower ball joint assembly. See «LOWER BALL JOINT ASSEMBLY»(ref-156462-S21650614062003071800000).
4. Install bolts, nuts and front axle assembly to shock absorber assembly. (Scheme 12) Insert bolt from rear side of vehicle and tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
5. Push front axle assembly toward outside of vehicle. Fit splined part of drive shaft assembly to front axle assembly. Insert drive shaft assembly into front axle assembly.
6. Install suspension arm lower sub-assembly No. 1. See «SUSPENSION ARM LOWER SUB-ASSEMBLY NO. 1»(ref-156462-S07961873212003071800000).
7. Install front disc.
8. Install front disc brake caliper assembly with bolts to steering knuckle. (Scheme 8) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
9. Install a NEW axle hub nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000). Using chisel and hammer, stake axle hub nut. (Scheme 13)
10. Remove bolts and disconnect disc brake caliper assembly from drive shaft assembly.
11. Remove front disc.
12. Using a dial indicator, check the backlash near center of axle hub. (Scheme 14) Maximum should be.0020 inches (.05 mm). If backlash exceeds maximum, replace bearing. See «AXLE HUB BEARING»(ref-156462-S04081820392003072100000).
13. Using dial indicator, check deviation at surface of axle hub outside hub bolt. (Scheme 15) Maximum should be.0020 inches (.05 mm). If backlash exceeds maximum, replace axle hub.
14. Install front disc.
15. Install front disc brake caliper assembly with bolts to steering knuckle. (Scheme 8) Tighten to specification. Install front disc brake caliper assembly with bolts to steering knuckle. (Scheme 8) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
16. Install speed sensor wire and front flexible hose No. 1 to shock absorber with bolt. (Scheme 16) Tighten to specification. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
17. Install sensor wire clamp.
18. Install speed sensor to steering knuckle with bolt. Tighten to specification. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
19. Install front wheel and tighten lug nuts to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
20. Inspect and adjust front wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
21. Check ABS speed sensor signal. For vehicles with VSC, see «ANTI-LOCK/VEHICLE SKID CONTROL - ES300»(ref-153183) in BRAKES. For vehicles without VSC, see «ANTI-LOCK - ES 300»(ref-153071) in BRAKES.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Remove front wheel.
2. Remove axle hub nut.
3. Disconnect speed sensor.
4. Disconnect disc brake caliper assembly. See appropriate article in «DISC»(ref-139125) article in BRAKES.
5. Remove cotter pin and nut from tie rod assembly. Using Special Tool (09628-62011), disconnect tie rod assembly from steering knuckle. (Scheme 9)
6. Disconnect suspension arm lower sub-assembly.
7. Remove axle assembly.
8. Remove lower ball joint assembly.
9. To inspect lower ball joint assembly, flip ball joint stub back and forth 5 times before installing nut. Using a torque wrench, turn nut continuously at a rate of 3-5 seconds per turn and take torque reading on 5th turn. Turning torque should be 8.7-30 Inch lb. (.98-3.43 N.m). (Scheme 17)

Scheme 17

Note. If the holes for cotter pin are not aligned, tighten nut further up to 60°.

1. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000) .
2. Inspect and adjust front wheel alignment. See appropriate WHEEL ALIGNMENT article.
3. Check ABS speed sensor signal. For vehicles with VSC, see «ANTI-LOCK/VEHICLE SKID CONTROL - ES300»(ref-153183) in BRAKES. For vehicles without VSC, see «ANTI-LOCK - ES 300»(ref-153071) in BRAKES.

1. Remove front wheel.
2. Remove nut and disconnect stabilizer link assembly from shock absorber assembly. If ball joint turns together with nut, use a hexagon wrench to hold stud. (Scheme 18)
3. Disconnect harness connector. Remove nuts, harness clamp and front shock absorber cap. (Scheme 19)
4. If disassembling shock absorber assembly on vehicles with Electric Modulated Suspension, use Special Tool (09817-33190) to loosen lock nut. If disassembling shock absorber assembly on vehicles without Electric Modulated Suspension, special tool is not needed. (Scheme 20)
5. Remove bolt, disconnect flexible hose No. 1 and speed sensor. (Scheme 7)
6. Remove nuts and bolts on lower side of shock absorber with coil spring. (Scheme 21)
7. Remove nuts on upper side of shock absorber with coil spring and remove shock absorber with coil spring. Be careful to not drop washers as front suspension center upper brace will make retrieval difficult. (Scheme 22)

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. Install shock absorber with coil spring as shown. (Scheme 23)
2. Install nuts to upper side of shock absorber with coil spring. (Scheme 22) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
3. Install bolts and nuts to lower side of shock absorber with coil spring. (Scheme 21) Stop bolt from rotating and tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
4. On vehicles with Electric Modulated Suspension, use Special Tool (09817-33190) to tighten lock nut. On vehicles without Electric Modulated Suspension, it is not necessary to use special tool. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
5. Install flexible hose No. 1 and speed sensor with bolt. (Scheme 7) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
6. Install shock absorber cap with nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000). Connect harness connector and install harness clamp. (Scheme 19)
7. Install stabilizer link assembly with nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000). If ball joint turns together with nut, use a hexagon wrench to hold stud. (Scheme 18)
8. Install front wheel and tighten lug nuts to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
9. Inspect and adjust front wheel alignment. See SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT.

Scheme 23

1. Remove front wheel.
2. Remove nuts and stabilizer link assembly. If ball joint turns with nut, use a hexagon wrench to hold stud. (Scheme 18)
3. Remove bolts and front stabilizer No. 1 bracket. (Scheme 24)
4. Remove cotter pin and nut of tie rod assembly. Using Special Tool (09628-62011), disconnect tie rod assembly from steering knuckle. (Scheme 9)
5. Using Special Tool (09023-00100), disconnect steering gear outlet return tube from rack and pinion power steering gear assembly. (Scheme 25)
6. Disconnect pressure feed tube assembly from rack and pinion power steering gear assembly. (Scheme 26)
7. Loosen bolt and remove clamp from steering column hole cover No. 1. (Scheme 27)
8. Disconnect steering column hole cover No. 2 from steering column hole cover No. 1. Loosen bolt. Place matchmarks on steering intermediate shaft sub-assembly and rack & pinion power steering gear assembly. Remove bolt and disconnect steering intermediate shaft sub-assembly.
9. Remove rack and pinion power steering gear assembly. See appropriate POWER RACK & PINION article in STEERING.
10. Remove stabilizer bar and stabilizer bush No. 1.
11. To inspect stabilizer link assembly, flip ball joint stub back and forth 5 times before installing nut. Using a torque wrench, turn nut continuously at a rate of 2-4 seconds per turn and take torque reading on 5th turn. Turning torque should be.4-17.4 Inch lb. (.05-1.96 N.m). (Scheme 28)

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Install stabilizer bar bush No. 1 to inner side of bushing stopper on stabilizer bar. (Scheme 29)
2. To complete installation, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).
3. Bleed power steering fluid. See appropriate POWER STEERING article in STEERING.
4. Check power steering system for leakage.
5. Inspect and adjust front wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 29

Removal & Installation

1. Remove engine assembly with transaxle. See 3.0L V6 article in ENGINE.
2. Remove nuts and transverse engine mounting insulator. (Scheme 30)
3. Remove bolts on front side of front suspension arm lower sub-assembly No. 1. (Scheme 31)
4. Remove bolt and nut on rear side of front suspension arm lower sub-assembly No. 1. (Scheme 32)
5. Remove front suspension arm lower sub-assembly No. 1.
6. Remove front lower arm bush stopper from front suspension arm lower arm sub-assembly No. 1.
7. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-156462-S20680701322003071700000).

Scheme 30

Scheme 31

Scheme 32